Apertured nonwoven webs

Abstract

An apertured nonwoven web is provided. The apertured nonwoven web comprises carded fibers, a first side, and a second side. The apertured nonwoven web defines a plurality of apertures therein. The apertures may each have a first side aperture size and a second side aperture size, and a ratio of the first side aperture size to the second side aperture size may be between about 1.15:1 to about 1:1.15. The plurality of apertures may have an aperture size regularity of about 1% to about 15%. The plurality of apertures may have an aperture shape regularity between about 1% to about 12%.

What is claimed is: 
     
       1. An absorbent article comprising:
 a nonwoven topsheet: 
 a liquid impermeable backsheet; and 
 an absorbent core positioned at least partially intermediate the topsheet and the backsheet; 
 wherein the topsheet comprises:
 carded fibers; 
 a first side; and 
 a second side; 
 wherein the topsheet defines a plurality of apertures; 
 wherein the apertures each have a first side aperture size and a second side aperture size, wherein a ratio of the first side aperture size to the second side aperture size is between about 1.05:1 and about 1:1.05, according to the Aperture Size Ratio Test; 
 wherein the plurality of apertures have an aperture size regularity of about 1.5% to about 6%, according to the Aperture Size Regularity Test; 
 wherein the plurality of apertures have an aperture shape regularity of between about 1.5% to about 4.5%, according to the Aperture Shape Regularity Test; and 
 wherein the topsheet has an opening rate of between 10% and 20%, according to the Opening Rate test. 
 
 
     
     
       2. The absorbent article of  claim 1 , wherein the topsheet comprises:
 a first nonwoven layer comprising the carded fibers, wherein the first nonwoven layer forms the first side; and 
 a second nonwoven layer joined to the first nonwoven layer, wherein the second nonwoven layer forms the second side. 
 
     
     
       3. The absorbent article of  claim 2 , wherein the first nonwoven layer is naturally hydrophobic. 
     
     
       4. The absorbent article of  claim 2 , wherein the first nonwoven layer is treated to be hydrophobic. 
     
     
       5. The absorbent article of  claim 1 , wherein the carded fibers comprise natural fibers. 
     
     
       6. The absorbent article of  claim 1 , wherein the carded fibers comprise cotton fibers. 
     
     
       7. The absorbent article of  claim 2 , wherein the second nonwoven layer is hydrophilic. 
     
     
       8. The absorbent article of  claim 2 , wherein the second nonwoven layer comprises synthetic fibers. 
     
     
       9. The absorbent article of  claim 1 , wherein perimeters of the apertures are substantially free of aperture perimeter tails. 
     
     
       10. The absorbent article of  claim 1 , wherein the plurality of apertures are between about 0.75% and about 2.5% occluded, according to the Aperture Clarity Test. 
     
     
       11. The absorbent article of  claim 1 , wherein the apertures each have an aperture wall thickness between the first side and the second side, and wherein a ratio of the aperture wall thickness to a thickness between the first side and the second side of the topsheet in a non-aperture area is between about 1:1 and about 1.5:1, according to the Aperture Wall Thickness Ratio Test. 
     
     
       12. The absorbent article of  claim 1 , wherein the apertures have an aperture wall thickness of between about 0.1 mm and about 0.75 mm, according to the Aperture Wall Thickness Measurement Test. 
     
     
       13. The absorbent article of  claim 1 , wherein the topsheet has a Rewet in the range of between about 0.01 g and about 0.5 g, according to the Rewet Test. 
     
     
       14. The absorbent article of  claim 1 , wherein the topsheet has a Run-Off in the range of about 1% to about 25%, according to the Run-Off Test. 
     
     
       15. The absorbent article of  claim 1 , wherein the topsheet has a Fluid Strike Through between about 1 s to about 6.5 s, according to the Fluid Strike Through Test. 
     
     
       16. An absorbent article comprising:
 a nonwoven topsheet: 
 a liquid impermeable backsheet; and 
 an absorbent core positioned at least partially intermediate the topsheet and the backsheet; 
 wherein the topsheet comprises:
 a first nonwoven layer comprising carded fibers, wherein the first nonwoven layer is hydrophobic and forms a first side; and 
 a second nonwoven layer joined to the first nonwoven layer, wherein the second nonwoven layer is hydrophilic and forms a second side; 
 wherein the topsheet defines a plurality of apertures; 
 wherein the apertures each have a first side aperture size and a second side aperture size, wherein a ratio of the first side aperture size to the second side aperture size is between about 1.05:1 and about 1:1.05, according to the Aperture Size Ratio Test; 
 wherein the plurality of apertures have an aperture size regularity of about 1.5% to about 6%, according to the Aperture Size Regularity Test; 
 wherein the plurality of apertures have an aperture shape regularity of between about 1.5% to about 4.5%, according to the Aperture Shape Regularity Test; and 
 wherein the topsheet has an opening rate of between 10% and 20%, according to the Opening Rate test. 
 
 
     
     
       17. The absorbent article of  claim 16 , wherein the carded fibers comprises cotton fibers. 
     
     
       18. The absorbent article of  claim 16 , wherein the second nonwoven layer comprises synthetic fibers. 
     
     
       19. The absorbent article of  claim 16 , wherein the plurality of apertures are between about 0.75% and about 2.5% occluded, according to the Aperture Clarity Test. 
     
     
       20. An absorbent article comprising:
 a nonwoven topsheet: 
 a liquid impermeable backsheet; 
 an absorbent core positioned at least partially intermediate the topsheet and the backsheet; and 
 an acquisition layer; 
 wherein the acquisition layer and the nonwoven topsheet are in a face-to-face relationship and form a laminate; 
 wherein the topsheet comprises:
 a first nonwoven layer comprising carded cotton fibers, wherein the first nonwoven layer is hydrophobic and forms a first side; and 
 a second nonwoven layer joined to the first nonwoven layer, wherein the second nonwoven layer is hydrophilic and forms a second side; 
 wherein the topsheet defines a plurality of apertures; 
 wherein the apertures each have a first side aperture size and a second side aperture size, wherein a ratio of the first side aperture size to the second side aperture size is between about 1.05:1 and about 1:1.05, according to the Aperture Size Ratio Test; 
 wherein the plurality of apertures have an aperture size regularity of about 1.5% to about 6%, according to the Aperture Size Regularity Test; 
 wherein the plurality of apertures have an aperture shape regularity of between about 1.5% to about 4.5%, according to the Aperture Shape Regularity Test; 
 wherein the plurality of apertures are between about 0.75% and about 2.5% occluded, according to the Aperture Clarity Test; and 
 wherein the topsheet has an opening rate of between 10% and 20%, according to the Opening Rate test.